Method and apparatus for producing trim panels

ABSTRACT

To form a seam of attractive appearance, a heated platen having a shaped lip acts to engage and press the central surface of an adhesively-backed sheet of a polymeric fabric against the top appearance surface of a panel and the peripheral edge of the sheet into a groove formed in the surface, the platen activating the adhesive and the lip forcing a portion of the adhesive inwardly adjacent to the sheet edge against one wall of the groove. An insertion blade presses a portion of the sheet edge towards the bottom of the groove, the blade acting as a heat shield to space and protect the other wall of the groove from the heated platen.

BACKGROUND OF THE INVENTION

This invention relates to an upholstered panel, such as for the interiorof an automobile, and more particularly, to an improved method andapparatus for making such panels in which a sheet of polymeric fabric isadhered to the appearance surface of a unitary panel and its edge joinedto a groove of the panel to form a seam of attractive appearance. Two ormore sheets of similar or different material can also be used to covercontiguous surface areas of such unitary panel, their edges being joinedto the groove to form an attractive seam.

Linings to cover otherwise unattractive surfaces of panels arewell-known and are in common usage in the building trade, in general,and in the automotive industry, such as for use in trim panels forlining the interior of automobiles. Trim panels for vehicles typicallyinclude a relatively rigid support base having a contoured appearancesurface which is covered by one or more sheets of thin material, such asa polymeric fabric, leather or vinyl. In these assemblies, it isimportant that the edges of the sheet, where joined to the panel, beattractive.

Generally, these assemblies can be made by injection molding a substratepanel directly onto the sheet or preforming the panel and joining thesheet material to the panel. Illustrative of the former approach is thetrim panel disclosed in Strapazzini U.S. Pat. No. 5,091,031. Althoughthe edges of the sheet material are joined first, this is a laborintensive step. The injection molding process has a disadvantage ofrequiring expensive mold apparatus.

Illustrative of the latter approach is the method disclosed in Repper etal. U.S. Pat. No. 4,779,390 wherein a unitary preformed panel ispartitioned into contiguous first and second surface areas by a groovepenetrating into the surface and the two surface areas successivelycovered by sheet material. In the method, the first surface area ismasked while adhesive is sprayed onto the second surface area, a firstsheet is positioned over the entire surface of the panel and the portioncovering the first surface area trimmed away, and a second sheet isadhered to the second surface area. The second sheet is adhered to thepanel, either by adhesive sprayed onto or provided on the back of thesheet, and the sheet edge is tucked into the groove.

According to one aspect of this method, since no heat treatment isnecessary, it is very important that the combined width of the sheetedges exceed the width of the groove whereby to provide a tight joint.Although the trim panel so formed may provide an acceptable product, thesteps of covering the first part of the panel surface, spraying adhesiveonto the second part of the surface, waiting for the adhesive to dry,cutting the unwanted sheet portion from the second part without cuttingthe panel, and joining the second sheet to the panel appears to becostly, either as being labor intensive or in the time involved betweensteps. The automotive industry is always looking for ways to produce acost-effective and attractive package.

Accordingly, it is therefore an object of the invention to provide anovel interior lining for automobiles, comprising different sheetmaterials.

A further object of the invention resides in the provision of novelmeans for thermal bonding a lining to a substrate, using different sheetmaterials, in an economical and attractive manner.

It is yet another object of the invention to provide an interior trimpanel comprising a unitary foundation panel having contiguous surfaceareas and a sheet of limp material bonded to at least one of the surfaceareas.

A further object of the invention is to provide an interior lining ofdifferent sheet material for automotive vehicles which are joined by aseam of attractive appearance.

A still further object of this invention is provision of an interiorlining having an attractive seam wherein the edge portion of the sheetmaterial forming the seam is retained in a receiving groove, or on acontoured surface of the panel extending between surface areas of thepanel, solely by adhesive.

According to the present invention, there is provided a method andapparatus for making a vehicle body door upholstery panel, the methodincluding the steps of providing a unitary foundation panel including atleast two contiguous surface areas partitioned .by a groove penetratinginto the panel to a predetermined depth, adhering an adhesive-backedsurface of a sheet of upholstery cover material to one surface area ofthe panel, pressing a heated platen against the sheet to cause theadhesive to become tacky and adhere to the one surface area, the platenhaving a peripheral lip to force a portion of the sheet against the wallof the sheet, and while the platen is pressed against the sheet drivingan insertion blade downwardly and into the groove to force the marginaledge portion of the sheet material into the groove, and holding theplaten against the sheet and insertion of the blade in the groove for asufficient period of time, the blade forming an air barrier to shieldthe sheet material on the panel from the heated platen.

Further objects, advantages and features of the present invention willbecome more fully apparent from the detailed consideration of thearrangement and construction of the constituent parts as set forth inthe following description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-section view in perspective, according tothe present invention, of a method of adhering a sheet of fabric to atrim panel, such as for use in the interior of an automobile vehicle.

FIG. 2 indicates the steps of the method for forming the trim panelaccording to this invention.

FIGS. 3 and 3A show in cross-section the sheet of fabric positioned onthe trim panel and detail of the sheet edge relative to a groove formedin the panel.

FIGS. 4 and 4A show in cross-section, a heated platen pressing thefabric against the panel.

FIGS. 5 and 5A show, in cross-section, the heated platen beingmaintained against the sheet and a tucking tool stuffing the edge of thesheet into the groove.

FIG. 6 is a cross-section view showing an alternate embodiment whereinthe heated platen alone is used to tuck the edges of the sheet materialinto the groove.

FIGS. 7 and 7A is a cross-section view, an alternate embodiment showingtwo sheets having their edges tucked into a groove.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, FIGS. 1-7 illustrate a method and apparatusfor assembly of an interior trim panel for an automobile. Although thetrim panel described herein is intended for use with a vehicle door (notshown), it is to be understood that such description is exemplary andcould be employed in other applications requiring securement of sheetmaterial to a support base and the edge of the sheet where joined to thebase presenting a seam of attractive appearance.

According to this invention, FIGS. 1-4 depict an apparatus 10 forfabricating a trim panel 12. The trim panel 12 comprises a generallyplanar unitary member 14 having contoured top and bottom surfaces 16 and18, the top surface 16 being the appearance surface and partitioned intotwo contiguous surface areas 20 and 22 by a preferably preformedcontinuous upwardly open groove 24, the surface area 20 encircling thesurface area 22. The groove 24 is generally oval in plan, U-shaped incross-section, and includes a pair of vertical walls 26 and 28 and awell 30, the vertical walls 26 and 28, respectively, forming a smoothtransition with the surface areas 20 and 22. It is to be understood thatin some applications a generally linear groove will be used to separatethe top surface into contiguous surface areas.

The panel member 14 may be made of a rigid material, such as fibrouspress board and the like and the surface covered by a sheet of limpmaterial, such as polyvinyl chloride, polymeric fabric or leather, allof the kind well known in the art. In the embodiment illustrated, thepanel is laminated and includes a bottom layer 32 of glass reinforcedurethane, an intermediate layer 34 of polypropylene foam, and a topsheet 36 of vinyl, the sheet 36 forming the top surface 16.

According to this invention a thin sheet of limp material is adapted tobe secured to the surface area 22. Preferably the sheet is comprised ofa polymeric fabric, such as exemplified by nylon and polypropylene or awool/cotton, and one surface thereof is pre-coated with a suitable heatactivatable adhesive which is ordinarily non-tacky in use. Althoughknown to those in the art, suitable adhesives are Product Number HC7675, available from PPG, Hughes Chemical Division, and Product Number2895, available from Worthen, Upaco Adhesive Division.

The sheet is pre-cut into a desired. Shape, represented in FIG. 1 by thenumber 38, the sheet conforming to the shape of the groove and having afree edge 40 adapted to be inserted into the groove. As shown best inFIG. 3A, the sheet material is represented at 38a and the adhesive onthe back of the sheet is represented at 38b.

The apparatus 10 includes a carriage 42 having an upper surface 44 forsupporting the panel member 14, a vertical press 46 having upper andlower heads 48 and 50 connected by a set of vertical tie rods 49, and aguide track 52 for guiding the carriage from a first position spacedfrom the press and into a second position between the heads of thepress. The carriage 42 has a plurality of locators 54 arranged on theupper surface 44 to engage the edge of the panel whereby to position thetrim panel relative to the carriage. In the carriage shown, a centrallocator 54a is provided to receive the cutout 14a formed in the panel,such as would be needed for a door handle. In this regard, the sheet 38would have a cutout 38a corresponding to the shape of the locator 54a.According to a feature of this invention, a U-shaped locator clamp 56 ishingedly mounted to the carriage and is adapted to assist in securingthe panel member 14 to the carriage and positioning part of the freeedge 40 of the sheet 38 in overlapping relation to a respective portionof the groove. The locator clamp 56 includes a pair of arms 56a havingforwardly angled surfaces 56b positionable adjacent to the groove toguide the edge of the sheet into position next to the groove.

According to this invention, a platen 58 and an insertion blade 60 areconnected to the upper head 48, each being adapted to be lowered intoengagement with the sheet. The platen 58 has a surface 62 conforming toand adapted to press the sheet 38 against the surface area 22 of thepanel member 14 and an outer periphery in the form of a preferablycontinuous lip 64 which conforms to the shape and cross-section of thegroove 24, the lip being dimensioned to extend partially into the grooveand press a portion of the sheet edge 40 against the surface of thevertical wall 28. The platen is adapted to be heated, such as byinternal heater coils (not shown), whereby to activate the adhesive andadhere the sheet to the panel. Importantly, the lip assures that part ofthe adhesive on the sheet and inwardly of the groove is activatedwhereby the sheet edge is held in the groove solely by an adhesive bond.

The insertion blade 60 is mounted for vertical movement relative to theplaten whereby to invade the groove to force the free edge portion ofthe sheet 38 downwardly into the groove 24. The insertion blade 60 ispreferably continuous, conforms to the shape of the groove 24, and hasinwardly and outwardly facing sides 66 and 68 and a forward end 70, theside 66 being spaced from the outer periphery of the platen 58 by an airgap 67 and the side 68 being spaced from the vertical wall 26 by an airgap 69. The forward end 70 is adapted to force the sheet edge and freeend portion of the sheet into the well of the groove.

An important feature of the insertion blade is its use both inpreventing the edge of the sheet from curling up and possiblymisadhering to the other vertical wall 38 and also as a heat shield.During the heating of the sheet and the adhesive, in higher temperatureapplications, it is possible that the heated platen could adverselyeffect the surface area 20 formed by the vinyl 36. The blade 60 shieldsthe vinyl from the platen heat, conducts heat directly from the platenand adhesive bond, and forms the vertical air barrier 69 between theblade ,side 68 and the vertical wall 28 whereby to inhibit transfer ofheat thereagainst.

Provided with the apparatus 10 is a driver to drive and hold the heatedplaten 58 and the blade 60 against the panel and the sheet, a mover tomove the carriage to and from the platen, and an electronic control forcontrolling the operation of the apparatus, including a timer forcontrolling the duration the platen is pressed against the sheet, thetemperature of the platen, the sequence by which the carriage ispositioned relative to the press, and the sequence by which the platenand the blade are positioned about the carriage and the sheet. Althoughnot shown, these elements are conventional and understood by one skilledin the art.

In operation, the heat activatable adhesive is roll-coated to one sideof the sheet and the sheet cut into the desired shape. The panel member14 is positioned on the carriage 42 by the locators 54, 54a and 56 andthereafter the adhesive side 38b of the sheet 38 is positioned on thepanel 14. The locator clamp 56 is rotated downwardly onto the topsurface 20 of the panel to clamp the panel to the carriage and the sheet38 is lowered into position on the surface 22, the opening 38c fittingabout the locator 54a and the sheet edge fitted within the arms 56a. Thecarriage is moved via the track 52 under the upper head 48 and intoposition vertically below the platen 58 and blade 60.

The platen 58 is preheated to a desired temperature, depending on thefabric, the thickness of the sheet; and the adhesive to be heated, andlowered vertically onto the top of the sheet, pressing the platensurface 62 against the sheet 38 and pressing the sheet against the panel14. As shown best in FIGS. 4 and 4A, the lip 64 invades into the groove24 and forces a marginal edge portion of the sheet edge against thegroove wall and the free edge 40 into the groove 24. Only the adhesiveon the portion of the sheet engaged by surface 62 and the lip 64 isactivated to adhere the sheet to the groove wall. That is, the platendoes not activate the adhesive portion on the sheet from that part ofthe sheet engaged by the lip to the free edge of the sheet.

Thereafter, as shown in FIG. 5A, the blade 60 is lowered, the blade end70 forcing the free edge 40 of the sheet downwardly into the groove. Theunadhered portion of the free edge is not retained by engagement withthe wall 26 of the groove because it is of minor width. The bladeprevents possible curling of the free edge thereby presenting anunattractive seam. The blade and platen are maintained in engagementwith the sheet for a time sufficient for the adhesive to be activated.Thereafter, the blade and platen are retracted and the carriage movedback to the first position.

In one application, the groove width was approximately 0.060 inch andthe thickness of the edge 40 of the sheet 38 was about 0.040 inch. Theplaten 58 was preheated to about 200 -300° F., with 245°-250° F. beingpreferable. The preheated platen was lowered onto and held against thesheet 38 for about 30 seconds. The blade was lowered about 1/2 secondafter the platen to drive the sheet edge into the groove and, maintainedin position with the platen to drain heat from the platen and shield thepanel from the heat.

The key to the method is selecting a temperature that is sufficient totransfer heat through the fabric to heat the adhesive to bond the sheetto the panel without disintegrating the fabric. The adhesive on thesheet portion corresponding to the inward extension of the lip isutilized as the sole means to retain the sheet edge in the groove. Theblade acts as a shield to thermally separate the platen from the otherwall of the groove, conducts heat through the blade material, andconvects heat through the vertical air wall separating the blade fromthe other wall of the groove.

FIG. 6 discloses another embodiment according to this invention wherein,depending on the operating temperature to achieve a thermal bond, andthe properties of the sheet material, the process may not require aninsertion blade. Generally this would be suitable for lower temperatureapplication wherein the blade is not needed to thermally shield theopposite wall of the groove. For example, polypropylene, which maydeteriorate at temperatures higher than 240°F.

In this embodiment, a platen 72 having a peripheral lip 74 is all thatis needed to press the sheet against the panel. The peripheral lip 74 ispreferably continuous and adapted to extend substantially to the bottomof the groove, whereby almost all of the sheet adhesive up to the edgeof the sheet will be activated by the platen and relied upon to adherethe sheet to the groove wall.

It should be noted that the appearance surface of the panel couldinclude a contoured transition (e.g., a sloping portion), instead of adefined groove, wherein the platen would bond the free edge of the sheetto the contour. In such application, since the sheet edge would beexposed, the sheet would preferably be comprised of a material that doesnot fray.

FIGS. 7 and 7A disclose another embodiment according to this inventionwherein two nontacky adhesively-backed sheets 76 and 78 of limp materialare adapted to be adhered to the respective surface areas 80 and 82 of apanel 84 having a groove 86. For example, one sheet could be vinyl andthe other sheet polymeric fabric. A first heated platen 88 has itsperipheral lip 90 adapted to force the sheet 76 against the surface area80 and into the groove, forcing a marginal edge portion of the sheet 76against the wall 92 of the groove 86. A second heated platen 94 has itsperipheral lip 96 adapted to force the second sheet 78 against thesurface area 82 and into the groove, forcing a marginal edge portion ofthe sheet 78 against the other wall 98 of the groove 86. In thisembodiment, the peripheral lips 90 and 96 are preferably continuous andthe adhesive on the back of each sheet 76 and 78 is activated and reliedupon to adhere the respective sheet to the panel.

Further, an insertion blade 100 is vertically inserted between theplaten 88 and 94 to draw heat from each of the platen. As before, an airgap separates the opposite sides of the blade from each of the platen.The platen 88 and 94 would be lowered into pressed engagement with theirrespective sheets 76 and 78, followed by insertion of the blade 100.Advantageously, each platen 88 and 94 could be operated at differenttemperatures, depending in part on the adhesive and sheet material.

The combined thickness of the marginal free edge portions of the firstand second sheets, are less than transverse width of the groove. Thatis, the marginal edge portions do not engage one another in the finishedproduct to be retained in the groove but yet provide a seam whichappears invisible.

While the above description constitutes the preferred embodiment of theinvention, it will be appreciated that the invention is susceptible tomodification, variation, and change without departing from the properscope or fair meaning of the accompanying claims.

What is claimed is:
 1. A method of installing a sheet of flexiblematerial on an appearance surface of a support panel, said appearancesurface being partitioned into contiguous first and second surface areasby a groove penetrating into the surface, the steps of the methodcomprising:coating one face of the sheet with a heat activatableadhesive, cutting the sheet into a desired shape and having a free edge,positioning the one face of said sheet onto the first surface area suchthat the free edge of the sheet is proximate to one vertical wall of thegroove, moving a platen into engagement with the other face of the sheetand pressing the one face of the sheet against the first surface area,heating the platen, maintaining the heated platen in pressed engagementwith the sheet for a time sufficient for the heat in the platen toactivate the adhesive and the adhesive to adhere to the first surfacearea, forcing a blade having opposite sides against the free edgeportion of the sheet and the edge portion of the sheet downwardly andinwardly of the groove such that one side of the blade is adjacent tothe edge portion of the sheet pressed against the one wall of the grooveand the other side of the blade is spaced from the opposite wall of thegroove by an air barrier, the blade shielding the opposite wall of thegroove from exposure to heat from the platen, and retracting the platenand the blade.
 2. The method as claimed in claim 1 wherein the step ofmoving the platen includes forcing the platen against a marginal edgeportion of the sheet and the marginal edge portion of the sheet edgeagainst said one vertical wall of said groove, the marginal edge portionbeing inwardly from the free edge of the sheet.
 3. The method as claimedin claim 1 wherein the heating step precedes the moving step.
 4. Themethod as claimed in claim 3 wherein the blade forcing step follows theplaten moving step.
 5. The method as claimed in claim 4 including thesteps of adhering a thin skin of polymeric material onto the entireappearance surface of said support panel including said groove, and thestep of positioning the sheet follows the step of adhering said skin,said sheet formed from a fabric material.
 6. The method as claimed inclaim 1 and further including the steps of:adhesively coating one faceof and cutting a second sheet of flexible material into a desired shapeand having a free edge, positioning the one face of said second sheet onthe second of said contiguous surface areas such that the free edgeportion thereof is proximate to the other vertical wall of the groove,and moving a second platen into pressed engagement with the other faceof said second sheet and maintaining the pressed engagement with thesecond surface area, said first and second platen being preheated andmoved substantially simultaneously against the respective sheets, andsaid blade substantially simultaneously forcing the free edge portionsof the two sheets into the groove and forming respective air barriersfor drawing the heat from each of the two platen away from the sheetmaterial.
 7. A method of forming a trim panel for the interior of anautomotive vehicle, the steps of the method comprising:providing asupport base having a contoured appearance surface comprised of apolymeric material, said support base including a continuous upwardlyopen groove penetrating into and dividing the appearance surface intocontiguous first and second surface areas, locating an adhesively-backedsheet of fabric having a free edge onto the first surface area with thefree edge partially overlapping the groove, moving a heated platenhaving a peripheral plate portion conforming to the shape of said grooveagainst the sheet, said platen causing said sheet to be pressed intoengagement against the first surface and the plate portion of the platenforcing the free edge into the groove such that a portion of the sheetinwardly of the free edge is pressed into engagement with the one wallof the groove, driving a blade into the groove and substantiallysimultaneously forcing the free edge towards the bottom of the groove,said blade driving step forming an air barrier between the blade and theother wall of the groove, the blade acting to shield the polymericmaterial on the other wall of the groove from the platen heat and theair barrier acting to dissipate heat conducted by the heated platen, andremoving the platen and blade.
 8. The method as claimed in claim 7including the step of maintaining the heated platen in pressedengagement with the sheet for a period of time sufficient to activatethe adhesive and form the sole means for retaining the sheet to thesupport base.
 9. The method as claimed in claim 7 wherein said blade isdriven into the groove after the adhesive has been activated and thefree edge portion adhered in part to the one wall of the groove.
 10. Themethod as claimed in claim 7 wherein said adhesively-backed sheet iscomprised of a polymeric fabric, said sheet being precoated with a heatactivatable adhesive and cut into the desired shape prior to saidlocating step.
 11. A method of making a vehicle body door upholsterypanel, the steps of the method comprising:providing a generally rigidunitary panel having top and bottom surface and an upwardly openvertical groove of predetermined depth penetrating into and partitioningthe top surface into contiguous first and second surface areas, thegroove and including generally vertically directed first and secondwalls which confront one another and form a transition with therespective first and second surface areas, positioning the adhesive backof an upholstery sheet having a center portion and a peripheral edgeportion on the panel such that the center portion is positioned on thefirst surface area and the edge portion is in partially overlappingrelation with the groove for insertion therein, the sheet having athickness that is less than the distance between the walls of the grooveand the adhesive being non-tacky in use and activatable by heat.pressing the center portion of the sheet against the first surface areaof the panel and the peripheral edge portion against the first wall ofthe groove, heat activating the adhesive on and adhering said center andmarginal portions of the sheet to said panel, substantiallysimultaneously shielding the second wall from the heat while driving theperipheral edge portion of the sheet not pressed against the first wallaway from the second wall and towards the bottom of the groove, andmaintaining the sheet in heated and pressed engagement with the paneluntil the sheet has adhered to the panel.
 12. A method of making avehicle body door upholstery panel, the method including the stepsof:providing a substantially rigid unitary panel, the panel including asubstantially uninterrupted groove penetrating into the top of the panelto a predetermined depth and partitioning the panel into contiguousfirst and second surface areas, positioning the adhesive back of a firstand second sheet of limp material onto the top of the panel and inintimate contact, respectively, with the first and second surface areas,the combined thickness of the marginal edge portions of said first andsecond sheets being less than the width of the groove when insertedtherein, and the marginal edge portion of each first and second sheetbeing of a width not exceeding the depth of the groove when insertedtherein, positioning heated platen against the first and second sheetsand pressing the adhesive backs against the respective first and secondsurface areas thereby activating the adhesive and causing the first andsecond sheet material to be adhered to the panel, and while said platenis in position and held in pressed relation against said sheet material,causing an insertion tool to be advanced downwardly and into the groove,the tool engaging and forcing the marginal edge portions of therespective first and second sheets against a respective groove wall andinto the groove, the insertion tool being at a temperature substantiallyless than said heated platen whereby to drain heat from the marginaledge portions.
 13. The method as claimed in claim 12 wherein the step ofpositioning the heated platen comprises substantially simultaneouslypressing a first and a second platen, respectively, against the firstand second sheets and the sheets against the first and second surfaceareas.
 14. The method as claimed in claim 13 wherein the first andsecond platen, respectively, are preheated to a first and secondtemperature.
 15. The method as claimed in claim 13 wherein the step ofpressing the heated platen against the first and second surface areas iscompleted prior to the step of inserting the insertion tool into thegroove.
 16. A method of forming a trim panel, comprising:providing asupport base having a contoured appearance surface and a slopingtransition surface forming first and second surface areas, locating theheat activatable adhesive back of a limp sheet of polymeric fabrichaving a free edge portion on the appearance surface with the free edgeportion overlapping the first surface area, spacing the peripheral andprimary plate portions of a heated platen in spaced relation to saidsheet, the peripheral plate portion conforming to the first surface areaof said transition surface and the primary plate portion conforming tothe appearance surface, pressing the platen against the support basewhereby the primary and peripheral plate portions press the sheetagainst the appearance and first surface areas, maintaining the platenagainst the sheet for a time sufficient to activate the heat, shieldingthe second surface area from the heat emanated from the heated platen,and removing the platen.
 17. Apparatus for installing a sheet offlexible material having a free edge on a generally planar trim panelhaving top and bottom surfaces, the top surface of the panel including acontinuous groove defining contiguous first and second surface areas andhaving first and second walls extending into the groove from therespective surface areas, the apparatus comprising:support means forsupporting the trim panel such that first surface area is positioned toreceive said sheet, a platen having a first surface portion conformingto the contour of said first surface area and a peripheral edge portionconforming to a portion of said first wall of said groove, said platenbeing adapted to move from a first position spaced from said panel and asecond position to engage and press said sheet against the panel andsaid portion of said first wall, heater means for heating the platen, aheat shield separated from and movable independently of said platen fordriving the free edge of said sheet into the groove and shielding thesecond wall from the heat of said platen, and control means forcontrolling the sequence of operation of the platen and the heat shield.18. The apparatus as claimed in claim 17 further comprising:carriagemeans for transporting said support means from a first position forloading and unloading said panel and said sheet and a second positionfor locating the panel and sheet relative to said platen and blade. 19.A method of forming a trim panel for the interior of an automotivevehicle, the steps of the method comprising:providing a support basehaving a contoured appearance surface comprised of a polymeric material,said support base including a continuous upwardly open groove thatpenetrates into and divides the appearance surface into contiguous firstand second surface areas, locating an adhesively-backed sheet having afree edge onto the first surface area with the free edge partiallyoverlapping the groove, moving a heated platen having a peripheral plateportion conforming to the shape of said groove against the sheet, saidplaten causing said sheet to be pressed into engagement against thefirst surface and the plate portion of the platen forcing the free edgeinto the groove such that a portion of the sheet inwardly of the freeedge is pressed into engagement with the one wall of the groove,maintaining the pressed engagement for a time sufficient for theadhesive to activate and the sheet to adhere to the support base,driving a blade into the groove and substantially simultaneously forcingthe free edge towards the bottom of the groove, said blade beingconfigured to form an air barrier between the other wall of the grooveand the blade, the blade forcing the free edge of the sheet into thegroove and drawing heat away from the adhered portion of the sheet, andremoving the platen and blade.
 20. The method as claimed in claim 16wherein the step of shielding the second surface area includesinterposing a heat shield between the first and second surface areas,the heat shield forming a first air barrier with the heated platen and asecond air barrier with the second surface, the air barriers and theheat shield operating to draw heat away from the first surface area andto shield the second surface area from the heat of the heated platen.21. The method as claimed in claim 20 wherein the step of interposing aheat shield includes forcing the free end of the sheet against thetransition surface.
 22. The apparatus as claimed in claim 17 furthercomprising:drive means for sequentially driving the platen against thesheet and the heat shield into the groove, said drive means beingoperatively associated with said control means, and timer means forcontrolling the time that heat is supplied to said heater means.